F BRAKES
SECTION
BR
BRAKE SYSTEM
A
B
C
D
E
CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for Brake System .................................. 3 PREPARATION ........................................................... 4 Special Service Tool ................................................. 4 Commercial Service Tools ........................................ 4 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 5 NVH Troubleshooting Chart ..................................... 5 BRAKE PEDAL .......................................................... 6 Inspection and Adjustment ....................................... 6 INSPECTION ........................................................ 6 ADJUSTMENT ...................................................... 6 Removal and Installation .......................................... 7 COMPONENTS .................................................... 7 REMOVAL FOR ADJUSTABLE BRAKE PEDAL..... 8 REMOVAL FOR NON-ADJUSTABLE BRAKE PEDAL .................................................................. 9 INSPECTION AFTER REMOVAL ......................... 9 INSTALLATION ..................................................... 9 BRAKE FLUID ...........................................................11 On-board Inspection ................................................11 LEVEL CHECK ....................................................11 Drain and Refill ........................................................11 Bleeding Brake System .......................................... 12 BRAKE PIPING AND HOSE .................................... 13 Hydraulic Circuit ..................................................... 13 Removal and Installation of Front Brake Piping and Brake Hose ............................................................ 13 REMOVAL ........................................................... 13 INSTALLATION ................................................... 14 Removal and Installation of Rear Brake Piping and Brake Hose ............................................................ 14 REMOVAL ........................................................... 14 INSTALLATION ................................................... 14 Inspection After Installation .................................... 15 BRAKE MASTER CYLINDER .................................. 16 On-board Inspection ............................................... 16
Revision: February 2007
LEAK INSPECTION ............................................ 16 Removal and Installation ........................................ 16 REMOVAL ........................................................... 16 INSTALLATION ................................................... 17 Disassembly and Assembly .................................... 17 DISASSEMBLY ................................................... 17 ASSEMBLY ......................................................... 17 BRAKE BOOSTER ................................................... 18 On-Vehicle Service ................................................. 18 OPERATING CHECK .......................................... 18 AIRTIGHT CHECK .............................................. 18 Removal and Installation ........................................ 19 REMOVAL ........................................................... 19 INSPECTION AFTER REMOVAL ....................... 20 INSTALLATION ................................................... 20 VACUUM LINES ....................................................... 21 Removal and Installation ........................................ 21 Inspection ............................................................... 21 VISUAL INSPECTION ......................................... 21 CHECK VALVE INSPECTION ............................. 22 FRONT DISC BRAKE ............................................... 23 On-vehicle Inspection ............................................. 23 PAD WEAR INSPECTION ................................... 23 Components ........................................................... 24 Removal and Installation of Brake Pad .................. 25 REMOVAL ........................................................... 25 INSTALLATION ................................................... 25 Removal and Installation of Brake Caliper and Disc Rotor ....................................................................... 25 REMOVAL ........................................................... 25 INSTALLATION ................................................... 25 Disassembly and Assembly of Brake Caliper ......... 26 DISASSEMBLY ................................................... 26 CALIPER INSPECTION ...................................... 27 ASSEMBLY ......................................................... 27 DISC ROTOR INSPECTION ............................... 28 Brake Burnishing .................................................... 29 REAR DISC BRAKE ................................................. 30 On-vehicle Inspection ............................................. 30 PAD WEAR INSPECTION ................................... 30
BR-1
2006 Pathfinder
BR
G
H
I
J
K
L
M
Components ........................................................... 31 Removal and Installation of Brake Pad ................... 32 REMOVAL ........................................................... 32 INSTALLATION .................................................... 32 Removal and Installation of Brake Caliper and Disc Rotor ....................................................................... 32 REMOVAL ........................................................... 32 INSTALLATION .................................................... 32 Disassembly and Assembly of Brake Caliper ......... 33 DISASSEMBLY ................................................... 33 CALIPER INSPECTION ...................................... 33
Revision: February 2007
ASSEMBLY ..........................................................34 DISC ROTOR INSPECTION ...............................34 Brake Burnishing .....................................................35 SERVICE DATA AND SPECIFICATIONS (SDS) ......36 General Specifications ............................................36 Brake Pedal ............................................................36 Brake Booster .........................................................36 Check Valve ............................................................37 Front Disc Brake .....................................................37 Rear Disc Brake ......................................................37
BR-2
2006 Pathfinder
PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
A
EFS00639
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. D WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. E ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. BR ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. G
Precautions for Brake System
EFS0063A
Recommended fluid is Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent. Refer to MA-11, "Fluids and Lubricants" . ● Do not reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas. ● To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. ● Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. ● Use flare nut wrench when removing and installing brake tube. ● Always check tightening torque when installing brake lines. ● Before working, turn ignition switch to OFF and disconnect connectors for ABS actuator and electric unit (control unit) or battery terminals. ● Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to BR-29, "Brake Burnishing" . WARNING: SBR686C ● Clean brake pads and shoes with a waste cloth, then wipe with a dust collector. ●
Revision: February 2007
BR-3
2006 Pathfinder
H
I
J
K
L
M
PREPARATION PREPARATION Special Service Tool
PFP:00002 EFS0063B
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Description Tool number (Kent-Moore No.) Tool name Measuring brake pedal height
— (J-46532) Brake and clutch pedal height measurement tool
LFIA0227E
Commercial Service Tools
EFS0063C
Tool name
Description
1. Flare nut crowfoot 2. Torque wrench
Removing and installing each brake piping a: 10 mm (0.39 in) / 12 mm (0.47 in)
S-NT360
Power tool
Removing nuts, bolts and screws
PBIC0190E
PBIC0191E
Revision: February 2007
BR-4
2006 Pathfinder
Symptom
Revision: February 2007 × × ×
Shake ×
Shimmy, Shudder × ×
BR-5 × × × × × PROPELLER SHAFT DIFFERENTIAL DRIVESHAFT SUSPENSION TIRES AND ROAD WHEEL STEERING
Rotor thickness variation
Rotor rust
Rotor deflection
Rotor deformation
Rotor runout
Rotor damage
Rotor imbalance
Shims damaged
Noise Pads - uneven wear
Possible cause and SUSPECTED PARTS
×
PS-5, "NVH Troubleshooting Chart"
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart
WT-4, "NVH Troubleshooting Chart"
FSU-4, "NVH Troubleshooting Chart" (FSU), RSU-4, "NVH Troubleshooting Chart" (RSU)
FAX-4, "NVH Troubleshooting Chart" (FAX), RAX-4, "NVH Troubleshooting Chart" (RAX)
FFD-6, "NVH Troubleshooting Chart" (FFD), RFD-7, "NVH Troubleshooting Chart" (RFD)
PR-3, "NVH Troubleshooting Chart"
BR-29, BR-35
BR-29, BR-35
BR-28, BR-34
BR-28, BR-34
BR-28, BR-34
BR-28, BR-34
BR-28, BR-34
BR-24, BR-31
BR-23, BR-30
BR-23, BR-30
Reference page
Pads - damaged
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003 EFS0063D
A
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. B
C
D
× × × × × ×
× × × ×
×: Applicable × × × ×
2006 Pathfinder
E
BR
G
H
I
J
K
L
M
BRAKE PEDAL BRAKE PEDAL Inspection and Adjustment
PFP:46501 EFS0063E
INSPECTION 1.
Inspect the brake pedal free height "H" from dash lower panel using Tool. Tool
2.
:
—
(J-46532)
Adjust the height referring to the following specifications. CAUTION: The adjustable pedal must be in the frontmost (closest to the floor) position for pedal height measurement.
WFIA0160E
Unit: mm (in)
Free height "H"
: 182.1 - 192.1 (7.17 - 7.56)
Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 lb) with engine running]
: 105 - 115 (4.13 - 4.53)
Clearance between pedal stopper and threaded end of stop lamp switch and ASCD cancel switch "C1 " or "C2 "
: 0.74 - 1.96 (0.029 - 0.077)
Pedal play "A"
: 3 - 11 (0.12 - 0.43)
ADJUSTMENT 1. 2.
Loosen the stop lamp switch and ASCD cancel switch by turning 45° counterclockwise. Loosen lock nut on the input rod, then turn input rod to adjust the pedal to specified height. When finished adjusting, tighten lock nut. CAUTION: Make sure that the screw portion of the end of input rod is located inside the clevis. Lock nut
3.
4.
5.
: 18.6 N·m (1.9 kg-m, 14 ft-lb)
With the pedal pulled up and held by hand, press the stop lamp switch and the ASCD cancel switch in until threaded ends conSBR229E tact pedal arm. With the threaded ends of the stop lamp switch and ASCD cancel switch contacting the pedal arm, turn the switches 45° clockwise to lock in place. CAUTION: Make sure that the gap "C1 or C2 " between the rubber stops and switch ends are within specification. Check the pedal play.
Revision: February 2007
BR-6
2006 Pathfinder
BRAKE PEDAL
6.
CAUTION: Make sure that the stop lamp goes off when the pedal is released. Start the engine and check the height of the brake pedal when depressing it.
Removal and Installation
A
EFS0063F
COMPONENTS
B
Adjustable Brake Pedal C
D
E
BR
G
H
I
J
K
LFIA0231E
1.
Brake pedal assembly
2.
Snap pin
3.
Clip
4.
Stop lamp switch
5.
Pedal pad
6.
Clevis pin
7.
ASCD cancel switch
Revision: February 2007
L
M
BR-7
2006 Pathfinder
BRAKE PEDAL Non-adjustable Brake Pedal
LFIA0232E
1.
Brake pedal assembly
2.
Snap pin
3.
Clip
4.
Stop lamp switch
5.
Pedal pad
6.
Clevis pin
7.
ASCD cancel switch
REMOVAL FOR ADJUSTABLE BRAKE PEDAL WARNING: Do not deform the brake tube. CAUTION: ● Before removal and installation the accelerator and brake pedals must be in the forward most position (closest to the floor). This is to align the base position of the accelerator and brake pedals. ● Do not disassemble the brake pedal adjusting mechanism. ● Avoid damage from dropping the brake pedal assembly during handling. ● Keep the brake pedal assembly away from water. 1. Remove the lower driver instrument panel. Refer to IP-10, "Removal and Installation" . 2. Remove the stop lamp switch and ASCD cancel switch from the pedal assembly.
Revision: February 2007
BR-8
2006 Pathfinder
BRAKE PEDAL 3.
Disconnect the adjustable brake pedal cable from the adjustable pedal. ● Release the two lock tabs, then pull the adjustable brake pedal cable to disconnect it from the adjustable brake pedal.
A
B
C LFIA0233E
4. 5.
D Remove snap pin and clevis pin from the clevis of the brake booster. Remove mounting nuts and the pedal assembly. E ● Temporarily install the nuts by hand to support the booster. CAUTION: ● Before removal and installation the accelerator and brake pedals must be in the frontmost position (closest to the floor). This is to align the base position of the accelerator and brake pedals. BR ● Do not disassemble the brake pedal adjusting mechanism. ● Avoid damage from dropping the brake pedal assembly during handling. G ● Keep the brake pedal assembly away from water.
REMOVAL FOR NON-ADJUSTABLE BRAKE PEDAL WARNING: Do not deform the brake tube. CAUTION: ● Do not disassemble the brake pedal assembly. ● Avoid damage from dropping the brake pedal assembly during handling. ● Keep the brake pedal assembly away from water. 1. Remove the lower driver instrument panel. Refer to IP-10, "Removal and Installation" . 2. Remove the stop lamp switch and ASCD cancel switch from the pedal assembly. 3. Remove snap pin and clevis pin from the clevis of the brake booster. 4. Remove mounting nuts and the pedal assembly. ● Temporarily install the nuts by hand to support the booster.
H
I
J
K
INSPECTION AFTER REMOVAL
L
Check brake pedal for following items. ● Crack or deformation of clevis pin stopper ● Clevis pin deformation ● Crack of any welded portion ● Brake pedal bend
M
SBR997
INSTALLATION 1.
Installation is in the reverse order of removal. ● Check the brake pedal for smooth operation. There should be no binding or sticking when applying or releasing the brake pedal. ● On models equipped with adjustable brake pedal, check the adjustable feature for smooth operation. There should be no binding or sticking when adjusting the brake pedal forward and backward.
Revision: February 2007
BR-9
2006 Pathfinder
BRAKE PEDAL ●
After installing the brake pedal assembly in the vehicle, be sure to adjust it. Refer to BR-6, "Inspection and Adjustment" .
Revision: February 2007
BR-10
2006 Pathfinder
BRAKE FLUID BRAKE FLUID On-board Inspection
PFP:KN100
A EFS0063G
LEVEL CHECK ● ● ● ●
Check that the brake fluid level in the reservoir tank is within specification, between the MAX and MIN lines as shown. Visually check around reservoir tank for fluid leaks. If fluid level is excessively low, check brake system for leaks. If brake warning lamp remains illuminated after the parking brake pedal is released, check the brake system for any brake fluid leaks.
B
C
D
LFIA0234E
Drain and Refill
E
EFS0063H
CAUTION: BR ● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" . ● Do not reuse drained brake fluid. ● Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so G when splashing it, immediately wipe off the area and wash away with water. ● Before servicing, disconnect battery negative cable. 1. Connect a vinyl tube to each bleed valve. H 2. Depress brake pedal, loosen each bleed valve, and gradually remove brake fluid. I
J
K SBR419C
3. 4.
Make sure there is no foreign material in reservoir tank, and refill with new brake fluid. Rest foot on brake pedal. Loosen bleed valve. Slowly depress pedal until it stops. Tighten bleed valve. Release brake pedal. Repeat this process a few times, then pause to add new brake fluid to master cylinder. Continue until new brake fluid flows out. Bleed air from brake system. Refer to BR-12, "Bleeding Brake System" .
L
M
SBR995
Revision: February 2007
BR-11
2006 Pathfinder
BRAKE FLUID Bleeding Brake System
EFS0063I
CAUTION: While bleeding, monitor the master cylinder brake fluid level. 1. Turn ignition switch OFF and disconnect battery negative cable. 2. Connect a vinyl tube to the rear right bleed valve. 3. Fully depress brake pedal 4 to 5 times. 4. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately. 5. Repeat steps 3 and 4 until no more air comes out. 6. Tighten bleed valve to the specified torque. Refer to BR-24, "Components" (front disc brake), BR-31, "Components" (rear disc brake). 7. Perform steps 2 to 6 at each wheel, with master cylinder reservoir tank filled at least half way, bleed air from the front left, rear left, and front right bleed valve, in that order.
Revision: February 2007
BR-12
2006 Pathfinder
BRAKE PIPING AND HOSE BRAKE PIPING AND HOSE Hydraulic Circuit
PFP:46210
A EFS0063J
B
C
D
E
BR
G
H
I WFIA0428E
1.
Actuator
2.
Master Cylinder
●
Flare nut
■
Union Bolt
3.
J
Brake Booster
CAUTION: ● All hoses and piping (tubes) must be free from excessive bending, twisting and pulling. ● Make sure there is no interference with other parts when turning steering both clockwise and counterclockwise. ● The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble the parts. Replace applicable part with a new one, if necessary. ● Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. ● Do not bend or twist brake hose sharply, or strongly pull it. ● When removing components, cover connections so that no dirt, dust, or other foreign matter gets in. ● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" . ● Do not reuse drained brake fluid.
Removal and Installation of Front Brake Piping and Brake Hose
EFS0063K
REMOVAL 1. 2. 3. 4.
Drain brake fluid. Refer to BR-11, "Drain and Refill" . Using a flare nut wrench, remove brake tube from brake hose. Remove lock plate and brake hose from bracket. Remove union bolt and then remove brake hose from caliper assembly.
Revision: February 2007
BR-13
2006 Pathfinder
K
L
M
BRAKE PIPING AND HOSE INSTALLATION 1.
Install brake hose by aligning with the protrusion on caliper assembly, and tighten union bolt to the specified torque. Refer to BR-13, "Hydraulic Circuit" . NOTE: Do not reuse copper washer.
LFIA0235E
2. 3. 4.
Insert brake hose end through bracket, then secure it to bracket with lock plate. Install brake tube to brake hose, then tighten flare nut to the specified torque using a flare nut wrench. Refill brake fluid and bleed air. Refer to BR-12, "Bleeding Brake System" .
LFIA0236E
Removal and Installation of Rear Brake Piping and Brake Hose
EFS0063L
REMOVAL 1. 2. 3. 4.
Drain brake fluid. Refer to BR-11, "Drain and Refill" . Using a flare nut wrench, remove brake tube from brake hose. Remove lock plate and brake hose from bracket. Remove union bolt, and then remove brake hose from caliper assembly.
INSTALLATION 1.
Install brake hose by aligning with the protrusion on caliper assembly, and tighten union bolt to the specified torque. Refer to BR-13, "Hydraulic Circuit" . NOTE: Do not reuse copper washer.
LFIA0237E
2. 3. 4.
Insert brake hose end through bracket, then secure it to bracket with lock plate. Install brake tube to brake hose, then tighten flare nut to the specified torque using a flare nut wrench. Refill brake fluid and bleed air. Refer to BR-12, "Bleeding Brake System" .
LFIA0238E
Revision: February 2007
BR-14
2006 Pathfinder
BRAKE PIPING AND HOSE Inspection After Installation
EFS0063M
CAUTION: If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part. 1. Check brake lines (tubes and hoses), and connections for fluid leaks, damage, twist, deformation, contact with other parts, and loose connections. Replace any damaged parts. 2. While depressing brake pedal under a force of 785 N (80 kg-f, 177 lb-f) with engine running for approximately 5 seconds, check for fluid leaks from each part.
A
B
C
D
E
BR
G
H
I
J
K
L
M
Revision: February 2007
BR-15
2006 Pathfinder
BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER On-board Inspection
PFP:46010 EFS0063N
LEAK INSPECTION ●
Check for leaks at master cylinder to brake booster attachment point, reservoir tank, and brake tube connections.
Removal and Installation
EFS0063O
Brake Master Cylinder
WFIA0411E
1.
Reservoir cap
2.
Strainer
3.
Fluid level sensor
4.
Reservoir tank
5.
Grommet
6.
Restriction washer
7.
Master cylinder sub-assembly
8.
Fluid pressure sensor
9.
O-ring
⇐
Front
10. Brake booster
CAUTION: Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.
REMOVAL 1. 2.
Drain brake fluid. Refer to BR-11, "Drain and Refill" . Disconnect harness connectors for fluid level sensor and pressure sensor.
Revision: February 2007
BR-16
2006 Pathfinder
BRAKE MASTER CYLINDER 3. 4.
Using a flare nut wrench, disconnect brake tube from master cylinder assembly. Remove master cylinder assembly mounting nuts and master cylinder assembly.
A
INSTALLATION ● ●
●
Installation is in the reverse order of removal. Refill brake fluid and bleed air. Refer to BR-12, "Bleeding Brake System" . CAUTION: ● Refill using recommended brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Do not reuse drained brake fluid. Adjust brake pedal. Refer to BR-6, "Inspection and Adjustment" .
Disassembly and Assembly
B
C
D
EFS0063P
DISASSEMBLY E CAUTION: ● Master cylinder cannot be disassembled. ● Remove reservoir tank only when absolutely necessary. Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem- BR bly body.
ASSEMBLY CAUTION: ● Never use mineral oils such as kerosene, gasoline during the cleaning and assembly process. ● Do not drop parts. If a part is dropped, do not use it. 1. Apply brake fluid or rubber grease to new grommets, then insert into master cylinder sub-assembly. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: Do not reuse grommet. 2. Install reservoir tank onto master cylinder assembly.
G
H
I
J
K
L
M
Revision: February 2007
BR-17
2006 Pathfinder
BRAKE BOOSTER BRAKE BOOSTER On-Vehicle Service
PFP:47200 EFS0063Q
OPERATING CHECK With engine stopped, change the vacuum to the atmospheric pressure by depressing brake pedal several times. Then with brake pedal fully depressed, start engine and when the vacuum pressure reaches the standard, make sure the clearance between brake pedal and floor panel decreases. CAUTION: Depressing pedal interval is approximately 5 seconds.
BRA0037D
AIRTIGHT CHECK Run engine at idle for approximately 1 minute, and stop it after applying vacuum to booster. Depress brake pedal normally to change the vacuum to the atmospheric pressure. Make sure distance between brake pedal and floor panel gradually increases. ● Depress brake pedal while engine is running and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds. CAUTION: Depressing pedal interval is approximately 5 seconds. ●
SBR365AA
Revision: February 2007
BR-18
2006 Pathfinder
BRAKE BOOSTER Removal and Installation
EFS0063R
A
Brake Booster
B
C
D
E
BR
G
H
I
J
K
L
M
LFIA0241E
1.
Brake booster hose
2.
Brake booster vacuum check valve
3.
Brake booster
4.
Lock nut
5.
Gasket
6.
Spacer block
REMOVAL CAUTION: ● Be careful not to deform or bend brake piping while removing and installing brake booster. ● Replace clevis pin if it is damaged. ● Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined during installation, dash panel may damage the threads. ● Attach the check valve in the correct direction. 1. Remove actuator and electric unit. Refer to BRC-62, "Removal and Installation" . 2. Remove brake piping from brake master cylinder. Revision: February 2007
BR-19
2006 Pathfinder
BRAKE BOOSTER 3. 4. 5. 6. 7.
Remove brake master cylinder. Refer to BR-16, "Removal and Installation" . Remove vacuum hose from brake booster. Refer to BR-21, "VACUUM LINES" . Remove brake pedal attachment snap pin and clevis pin from inside the vehicle. Remove nuts on brake booster and brake pedal assembly. Remove brake booster assembly from dash panel.
INSPECTION AFTER REMOVAL Output Rod Length Inspection 1. 2.
Using a suitable vacuum pump, apply a vacuum of -66.7 kPa (500 mmHg, -19.69 inHg) to brake booster. Check output rod length. Standard dimension when vacuum – 66.7 kPa (– 500 mmHg, – 19.69 inHg)
: 15.6 − 15.9 mm (0.614 − 0.626 in)
SBR208E
INSTALLATION 1.
Loosen lock nut to adjust input rod length so that the length "B" satisfies the specified value. Length "B"
: 150 mm (5.91 in)
2.
After adjusting "B", temporarily tighten lock nut and install booster assembly to the vehicle. ● Install a gaskets and spacer block between booster assembly and the dash panel. 3. Connect brake pedal with clevis of input rod. 4. Install brake booster nuts. 5. Install brake piping from brake master cylinder to actuator and electric unit. Refer to BR-13, "Hydraulic Circuit" . 6. Connect vacuum hose to brake booster. 7. Install master cylinder to booster assembly. Refer to BR-19, "Removal and Installation" . 8. Adjust the height of brake pedal. Refer to BR-6, "Inspection and Adjustment" . 9. Tighten input rod lock nut. 10. Refill new brake fluid and bleed air. Refer to BR-12, "Bleeding Brake System" .
Revision: February 2007
BR-20
SGIA0060E
2006 Pathfinder
VACUUM LINES VACUUM LINES Removal and Installation
PFP:41920
A EFS0063S
Brake Booster Vacuum Hose B
C
D
E
BR
G WFIA0332E
1.
1. 2. 3. 4.
Brake booster hose
2.
Brake booster hose clip
3.
Brake booster vacuum check valve
Disconnect brake booster hose from hose clip mounted on bracket. Release clips and disconnect brake booster hose. Remove check valve from brake booster. Installation is in the reverse order of removal. CAUTION: ● Insert vacuum hose for at least 24 mm (0.94 in). ● Do not use lubricating oil during assembly.
H
I
J
K
L
M SBR225B
Inspection
EFS0063T
VISUAL INSPECTION Check for improper assembly, damage and deterioration.
Revision: February 2007
BR-21
2006 Pathfinder
VACUUM LINES CHECK VALVE INSPECTION Airtightness Inspection Use a suitable vacuum pump to check. Connect to brake booster side of check valve. Check valve specification
: Vacuum decrease should be within 1.3 kPa (10 mmHg, 0.39 inHg) for 15 seconds under a vacuum of – 66.7 kPa (– 500 mmHg, – 19.69 inHg)
LFIA0217E
Revision: February 2007
BR-22
2006 Pathfinder
FRONT DISC BRAKE FRONT DISC BRAKE On-vehicle Inspection
PFP:41000
A EFS0063U
PAD WEAR INSPECTION ●
Inspect the thickness of pad through cylinder body inspection hole. Use a scale for inspection if necessary. Standard thickness Repair limit thickness
B
: 10.0 mm (0.394 in) : 2.0 mm (0.079 in)
C
D
BRA0010D
E
BR
G
H
I
J
K
L
M
Revision: February 2007
BR-23
2006 Pathfinder
FRONT DISC BRAKE Components
EFS0063V
Front Disc Brake Caliper and Pads
WFIA0537E
1.
Sliding pin bolt
2.
Cylinder body
3.
4.
Piston
5.
Piston boot
6.
Piston seal Sliding pin
7.
Sliding pin boot
8.
Torque member bolt
9.
Torque member
10. Upper pad retainer
11. Outer shim
12. Inner brake pad
13. Outer brake pad
14. Lower pad retainer
15. Shim cover
16. Bleed valve
17. Cap
18. Copper washers
19. Union bolt
20. Brake hose
21. Pad return spring
⇐
: Front
WARNING: Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne particles or other materials. Revision: February 2007
BR-24
2006 Pathfinder
FRONT DISC BRAKE CAUTION: ● While removing cylinder body never depress brake pedal because piston will pop out. ● It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of cylinder body. In this case, hang cylinder body with a wire so as not to stretch brake hose. ● Do not damage piston boot. ● Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-29, "Brake Burnishing" .
Removal and Installation of Brake Pad
A
B
C
EFS0063W
REMOVAL 1. 2. 3. 4.
Remove wheel and tire using power tool. Remove master cylinder reservoir cap. Remove lower sliding pin bolt using power tool. Suspend cylinder body with a wire and remove pad return spring, pads, shim, shim covers, and retainers from torque member.
INSTALLATION 1. 2.
3.
4. 5. 6. 7. 8.
4. 5.
H
I
J
K
L
M
Remove wheel and tire using power tool. Drain brake fluid as necessary. Refer to BR-11, "Drain and Refill" . NOTE: Do not remove union bolt unless removing cylinder body from vehicle. Remove union bolt as necessary and torque member bolts, then remove cylinder body from the vehicle. NOTE: ● Position cylinder body aside using suitable wire, as necessary. ● When servicing brake caliper, remove sliding pin bolts and caliper from torque member. Remove torque member. Remove disc rotor.
INSTALLATION CAUTION: ● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" . ● Do not reuse drained brake fluid. Revision: February 2007
G
EFS0063X
REMOVAL
3.
E
BR
Apply Molykote M-77 grease between outer brake pad plate and shim, then attach shim and shim covers to brake pads. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . Attach pad retainer to torque member, then install brake pad, shims and pad return spring. CAUTION: When attaching pad retainer, attach it firmly so that it is flush with torque member, as shown. Push pistons into cylinder body. NOTE: Using a disc brake piston tool (commercial service tool), etc., makes it easier to push in piston. CAUTION: PFIA0273E By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the surface of reservoir tank. Remove wire then swing cylinder body down over brake pad assemblies. Install lower sliding pin bolt and tighten to specification. Refer to BR-24, "Components" . Check brake for drag. Inspect fluid level, then install master cylinder reservoir cap. Install wheel and tire. Refer to WT-7, "Rotation" .
Removal and Installation of Brake Caliper and Disc Rotor 1. 2.
D
BR-25
2006 Pathfinder
FRONT DISC BRAKE 1. 2. 3. 4.
Install disc rotor. Install torque member and tighten to specification. Refer to BR-24, "Components" . Install sliding pin bolts, if removed. Install cylinder body, then tighten sliding pin bolts to the specified torque. Refer to BR-24, "Components" . CAUTION: When attaching cylinder body to the vehicle, wipe any oil off knuckle spindle, washers and cylinder body attachment surfaces.
LFIA0239E
5.
Install brake hose to cylinder body, if removed, then tighten union bolt to the specified torque. Refer to BR-24, "Components" . CAUTION: ● Do not reuse copper washers for union bolt. ● Attach brake hose to cylinder body together with union bolt and washers.
LFIA0235E
6. 7.
Refill with new brake fluid as necessary and bleed air. Refer to BR-12, "Bleeding Brake System" . Install wheel and tire. Refer to WT-7, "Rotation" .
Disassembly and Assembly of Brake Caliper
EFS0063Y
DISASSEMBLY 1.
Remove sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque member.
2. 3.
Remove sliding pins and sliding pin boots from torque member. Place a wooden block as shown, and blow air from union bolt mounting hole to remove pistons and piston boots. CAUTION: Do not get your fingers caught in piston.
BRB0032D
Revision: February 2007
BR-26
2006 Pathfinder
FRONT DISC BRAKE 4.
Using a suitable tool, remove piston seal from cylinder body. CAUTION: ● Be careful not to damage cylinder inner wall. ● Do not reuse piston seal.
A
B
C SFIA0141E
D
CALIPER INSPECTION Cylinder Body
CAUTION: E ● Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Check inside surface of cylinder for score, rust, wear, damage or foreign materials. If any of the BR above conditions are observed, replace cylinder body. ● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. G
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
H
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed. CAUTION: Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are stuck to sliding surface.
I
Sliding Pins, and Sliding Pin Boots
J
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present, replace the affected part. CAUTION: Trailing/upper sliding pin must be replaced at each service.
K
ASSEMBLY
L
CAUTION: Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling. 1. Apply clean brake fluid to new piston seal and insert seal into groove on cylinder body. CAUTION: Do not reuse piston seal.
M
SFIA2399E
Revision: February 2007
BR-27
2006 Pathfinder
FRONT DISC BRAKE 2.
Apply clean brake fluid to piston boot. Cover the piston end with piston boot, and then install cylinder side lip on piston boot securely into a groove on cylinder body. CAUTION: Do not reuse piston boot.
SFIA2432E
3.
Apply brake fluid to piston, then install piston into cylinder body and insert piston boot side lip into groove of piston as shown. CAUTION: Press the piston evenly to prevent damage to cylinder wall.
WFIA0211E
4.
5.
6.
Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove. CAUTION: Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed. Install sliding pins and sliding pin boots to torque member. CAUTION: Trailing/upper sliding pin must be replaced at each service. Install cylinder body. Tighten sliding pin bolt to the specified torque. Refer to BR-24, "Components" .
DISC ROTOR INSPECTION Visual Inspection Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace applicable part.
Runout Inspection 1. 2.
Using wheel nuts, fix disc rotor to wheel hub in two or more positions. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in) inside the disc edge.] Runout limit (on vehicle)
3.
4.
: 0.05 mm (0.0020 in)
NOTE: Make sure that wheel bearing axial end play is within the specifications before measuring runout. Refer to FAX-5, "WHEEL BEARING INSPECTION" . If runout is outside the limit, find the minimum runout point by shifting mounting positions of disc rotor and wheel hub by one hole. If runout still out of specification, turn rotor with on-car brake lathe.
Revision: February 2007
BR-28
BRA0013D
2006 Pathfinder
FRONT DISC BRAKE Thickness Inspection A
Using a micrometer, check thickness of disc rotor. If thickness is either at or below the wear limit, or exceeds maximum uneven wear, replace disc rotor. Standard thickness
: 28.0 mm (1.102 in)
Repair limit thickness Maximum uneven wear (Measured at 8 positions)
: 26.0 mm (1.024 in) : 0.015 mm (0.0006 in)
B
C
SBR020B
Brake Burnishing
D
EFS006G8
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after E replacing pads, or if a soft pedal occurs at very low mileage. CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution. BR 1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH). 2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds. G 3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping. 4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure. H
I
J
K
L
M
Revision: February 2007
BR-29
2006 Pathfinder
REAR DISC BRAKE REAR DISC BRAKE On-vehicle Inspection
PFP:44000 EFS0063Z
PAD WEAR INSPECTION ●
Inspect the thickness of pad through cylinder body inspection hole. Use a scale for inspection if necessary. Standard thickness Repair limit thickness
: 11.0 mm (0.433 in) : 2.0 mm (0.079 in)
BRA0010D
Revision: February 2007
BR-30
2006 Pathfinder
REAR DISC BRAKE Components
EFS00640
A
Rear Disc Brake Caliper and Pads
B
C
D
E
BR
G
H
I
J
K
L
M
WFIA0538E
1.
Union bolt
2.
Brake hose
3.
4.
Sliding pin bolt
5.
Cap
6.
Copper washers Bleed valve
7.
Cylinder body
8.
Sliding pin
9.
Piston seal
10. Piston
11. Piston boot
12. Torque member
13. Torque member bolt
14. Pad retainer
15. Outer shim
16. Outer brake pad
17. Inner brake pad
18. Inner shim
⇐
: Front
WARNING: Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne particles or other materials.
Revision: February 2007
BR-31
2006 Pathfinder
REAR DISC BRAKE CAUTION: ● While removing cylinder body, never depress brake pedal because piston will pop out. ● It is not necessary to remove bolts on torque member and brake hose except for disassembly or replacement of cylinder body. In this case, hang cylinder body with a wire so as not to stretch brake hose. ● Do not damage piston boot. ● Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft pedal occurs at very low mileage. Refer to BR-35, "Brake Burnishing" .
Removal and Installation of Brake Pad
EFS00641
REMOVAL 1. 2. 3. 4.
Remove wheel and tire using power tool. Remove master cylinder reservoir cap. Remove lower sliding pin bolt using power tool. Suspend cylinder body with a wire and remove pads, shims and retainers from torque member.
INSTALLATION 1. 2.
3.
4. 5. 6. 7. 8.
Attach shims to brake pads. Attach pad retainer to torque member, then install brake pad and shim assemblies. CAUTION: When attaching pad retainer, attach it firmly so that it is flush with torque member, as shown. Push piston into cylinder body. NOTE: Using a disc brake piston tool (commercial service tool), etc., makes it easier to push in piston. CAUTION: By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the surface of reservoir tank. Remove wire then swing cylinder body down over brake pad assemblies. Install lower sliding pin bolt and tighten to specification. Refer to BR-31, "Components" . Check brake for drag. Inspect fluid level, then install master cylinder reservoir cap. Install wheel and tire. Refer to WT-7, "Rotation" .
Removal and Installation of Brake Caliper and Disc Rotor
PFIA0273E
EFS00642
REMOVAL 1. 2. 3. 4. 5.
Remove wheel and tire using power tool. Drain brake fluid. Refer to BR-11, "Drain and Refill" . Remove union bolt and mounting bolts, and remove cylinder body. Remove torque member. Remove disc rotor.
LFIA0211E
INSTALLATION CAUTION: ● Refill with new brake fluid. Refer to MA-11, "Fluids and Lubricants" .
Revision: February 2007
BR-32
2006 Pathfinder
REAR DISC BRAKE ●
1. 2. 3.
4.
5. 6.
Do not reuse drained brake fluid. Install disc rotor. Install torque member and tighten to specification. Refer to BR-31, "Components" . Install cylinder body to the vehicle, and tighten mounting bolts to specification. CAUTION: Before installing cylinder body to the vehicle, wipe off mounting surface of cylinder body. Install brake hose to cylinder body and tighten union bolt to specification. Refer to BR-31, "Components" . CAUTION: ● Do not reuse copper washer for union bolt. ● Securely attach brake hose to protrusion on cylinder body. Refill new brake fluid and bleed air. Refer to BR-12, "Bleeding Brake System" . Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper
EFS00643
A
B
C
D
E
DISASSEMBLY 1. 2. 3.
Remove pads from cylinder body. Remove sliding sleeve and boot from cylinder body. Place a wooden block as shown, and blow air from union bolt mounting hole to remove piston and piston boot. CAUTION: Do not get your fingers caught in piston.
BR
G
H
I BRD0041D
4.
Using a suitable tool, remove piston seal from cylinder body. CAUTION: Be careful not to damage cylinder inner wall.
J
K
L
PFIA0269E
CALIPER INSPECTION Cylinder Body CAUTION: ● Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene. ● Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the above conditions are observed, replace cylinder body. ● Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.
Torque Member Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston CAUTION: ● Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are stuck to sliding surface. Revision: February 2007
BR-33
2006 Pathfinder
M
REAR DISC BRAKE ●
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.
Sliding Pin Bolts and Sliding Pin Boots Make sure there is no wear, damage, or cracks in sliding sleeve and sliding sleeve boots, and if there are, replace them.
ASSEMBLY CAUTION: Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling. 1. Apply clean brake fluid to new piston seal and insert into groove on cylinder body. CAUTION: Do not reuse piston seal.
WFIA0210E
2.
Apply brake fluid to piston and to piston boot, then install piston boot into piston groove. CAUTION: Do not reuse piston boot.
WFIA0211E
3.
4.
Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove. CAUTION: Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed. Install sliding boots and sleeves to cylinder body.
DISC ROTOR INSPECTION Visual Inspection Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is detected, replace applicable part.
Runout Inspection 1. 2.
Using wheel nuts, install disc rotor to wheel hub in 2 or more positions. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in) inside disk edge.] Runout limit (on vehicle)
3.
4.
: 0.07 mm (0.0028 in)
NOTE: Make sure that wheel bearing axial end play is within the specification before measuring runout. Refer to RAX-5, "On-Vehicle Inspection and Service" . If runout is outside the limit, find the minimum runout point by shifting mounting positions of disc rotor and wheel hub by one hole. If runout still out of specification, turn rotor with on-car brake lathe.
Revision: February 2007
BR-34
BRA0013D
2006 Pathfinder
REAR DISC BRAKE Thickness Inspection A
Using a micrometer, check thickness of disc rotor. If thickness is either at or below the wear limit, or exceeds maximum uneven wear, replace disc rotor. Standard thickness
: 18.0 mm (0.709 in)
Wear limit Maximum uneven wear (measured at 8 positions)
: 16.0 mm (0.630 in) : 0.015 mm (0.0006 in)
B
C
SBR020B
Brake Burnishing
D
EFS006G9
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after E replacing pads, or if a soft pedal occurs at very low mileage. CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution. BR 1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH). 2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds. G 3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping. 4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure. H
I
J
K
L
M
Revision: February 2007
BR-35
2006 Pathfinder
SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
PFP:00030 EFS00644
Unit: mm (in) Front brake
Brake model
CLZ33VB
Rotor outer diameter × thickness
Rear brake
296 × 28 (11.654 × 1.102)
Pad Length × width × thickness
111.0 × 73.5 × 10.0 (4.73 × 2.894 × 0.394)
Cylinder bore diameter (each)
46.4 (1.83)
Brake model
CLZ14VB
Rotor outer diameter × thickness
308 × 18 (12.126 × 0.709)
Pad Length × width × thickness
83.0 × 33.0 × 11.0 (3.268 × 1.299 × 0.433)
Cylinder bore diameter Control valve
Valve model
Brake booster
Booster model
38.1 (1.50) Electric brake force distribution C215T
Diaphragm diameter
215 (8.46) Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
Recommended brake fluid
Brake Pedal
EFS00645
Unit: mm (in)
WFIA0160E
Free height "H"
182.1 - 192.1 (7.17 - 7.56)
Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 lb) with engine running] Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch "C1 " or “C2 ” Pedal play "A"
105 - 115 (4.13 - 4.53) 0.74 - 1.96 (0.029 - 0.077) 3 - 11 (0.12 - 0.43)
Brake Booster
EFS00646
Unit: mm (in) 15.6 − 15.9 (0.614 − 0.626)
Input rod installation standard dimension
Revision: February 2007
BR-36
2006 Pathfinder
SERVICE DATA AND SPECIFICATIONS (SDS) Check Valve
EFS00647
A Vacuum leakage [at vacuum of -66.7 kPa(-500 mmHg, -19.69 inHg)]
Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Front Disc Brake
EFS00648
B
Unit: mm (in) Brake model Brake pad
Disc rotor
CLZ33VB Standard thickness (new)
10.0 (0.394)
Repair limit thickness
2.0 (0.079)
Standard thickness (new)
28.0 (1.102)
Repair limit thickness
26.0 (1.024)
Maximum uneven wear (measured at 8 positions)
0.015 (0.0006)
Runout limit (with it attached to the vehicle)
0.05 (0.0020)
Rear Disc Brake
C
D
E EFS00649
Unit: mm (in) Brake model Brake pad
Disc rotor
BR
CLZ14VB Standard thickness (new)
11.0 mm (0.433 in)
Repair limit thickness
2.0 mm (0.079 in)
Standard thickness (new)
18.0 mm (0.709 in)
Repair limit thickness
16.0 mm (0.630 in)
Maximum uneven wear (measured at 8 positions)
0.015 mm (0.0006 in)
Runout limit (with it attached to the vehicle)
0.07 mm (0.0028 in)
G
H
I
J
K
L
M
Revision: February 2007
BR-37
2006 Pathfinder
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: February 2007
BR-38
2006 Pathfinder
